Methods and apparatuses for producing metallic powder material

A method for producing a titanium alloy powder, the method comprising:

• supplying feed materials to a water-cooled copper melting hearth;
• melting the feed materials in the water-cooled copper melting hearth with a first plasma torch, thereby producing a molten titanium alloy material in the water-cooled copper melting hearth;
• passing at least a portion of the molten titanium alloy material from the water-cooled copper melting hearth to a water-cooled copper atomizing hearth;
• heating the molten titanium alloy material in the water-cooled copper atomizing hearth with a second plasma torch;
• passing at least a portion of the molten titanium alloy material directly from the water-cooled copper atomizing hearth through a cold induction guide to a gas-atomizing nozzle, wherein the cold induction guide is directly coupled to, and disconnectable from, the water-cooled copper atomizing hearth, and wherein the cold induction guide comprises:
• a passage in direct fluid communication with the water-cooled copper atomizing hearth and the gas-atomizing nozzle, the passage comprising a water-cooled wall containing molten titanium alloy material received from the water-cooled copper atomizing hearth;
• and
• an induction coil that selectively heats at least a portion of the molten titanium alloy material contained in the passage and controls solidification and flow of the molten titanium alloy material in the passage;
• impinging a gas jet onto a stream of the molten titanium alloy material in the gas-atomizing nozzle, thereby dispersing the stream of molten titanium alloy material into molten titanium alloy droplets;
• solidifying the molten titanium alloy droplets, thereby forming a titanium alloy powder;
• and
• collecting the titanium alloy powder.

A method for producing an alloy powder, the method comprising:

• supplying feed materials to a water-cooled copper melting hearth;
• melting the feed materials in the water-cooled copper melting hearth with a first plasma torch, thereby producing a molten alloy material in the water-cooled copper melting hearth;
• passing at least a portion of the molten alloy material from the water-cooled copper melting hearth to a water-cooled copper atomizing hearth;
• heating the molten alloy material in the water-cooled copper atomizing hearth with a second plasma torch;
• passing at least a portion of the molten alloy material directly from the water-cooled copper atomizing hearth through a cold induction guide to a gas-atomizing nozzle, wherein the cold induction guide is directly coupled to, and disconnectable from, the water-cooled copper atomizing hearth, and wherein the cold induction guide comprises:
• a passage in direct fluid communication with the water-cooled copper atomizing hearth and the gas-atomizing nozzle, the passage comprising a water-cooled wall containing molten alloy material received from the water-cooled copper atomizing hearth;
• and
• an induction coil that selectively heats at least a portion of the molten alloy material contained in the passage and controls solidification and flow of the molten alloy material in the passage;
• impinging a gas jet onto a stream of the molten alloy material in the gas-atomizing nozzle, thereby dispersing the stream of molten alloy material into molten alloy droplets;
• solidifying the molten alloy droplets, thereby forming an alloy powder;
• and
• collecting the alloy powder.

A method for producing a metallic powder, the method comprising:

• supplying feed materials to a water-cooled copper melting hearth;
• melting the feed materials in the water-cooled copper melting hearth with a first plasma torch or a first electron beam gun, thereby producing a molten metallic material in the water-cooled copper melting hearth;
• passing at least a portion of the molten metallic material from the water-cooled copper melting hearth to a water-cooled copper atomizing hearth;
• heating the molten metallic material in the water-cooled copper atomizing hearth with a second plasma torch or a second electron beam gun;
• passing at least a portion of the molten metallic material directly from the water-cooled copper atomizing hearth through a cold induction guide to an atomizing nozzle, wherein the cold induction guide is directly coupled to, and disconnectable from, the water-cooled copper atomizing hearth, and wherein the cold induction guide comprises:
• a passage in direct fluid communication with the water-cooled copper atomizing hearth and the atomizing nozzle, the passage comprising a water-cooled wall containing molten metallic material received from the water-cooled copper atomizing hearth;
• and
• an induction coil that selectively heats at least a portion of the molten metallic material contained in the passage and controls solidification and flow of the molten metallic material in the passage;
• forming a spray of molten metallic material droplets in the atomizing nozzle;
• solidifying the molten metallic droplets, thereby forming a metallic powder;
• and
• collecting the metallic powder.